Product conveyor system

ABSTRACT

Product conveyor system wherein a plurality of separate product carriers are provided in the form of generally flat rectangular grates. Each carrier is moved by an upward shuttle from a lowermost station of a first stack and thence through a plurality of intermediate stations to an uppermost station of the first stack, thence by a first transverse shuttle to the uppermost station of a second stack, thence by downward shuttle through a plurality of intermediate stations to a lowermost station of the second stack and thence by a second transverse shuttle back to the lowermost station of the first stack. Loading and unloading conveyors deliver and receive products to and from the lowermost carriers of the first and second stacks. Important features relate to the construction and operation of the shuttles and to the delivery of the product from the loading conveyor and to the unloading conveyor.

United States Patent [1 1 Batik PRODUCT CONVEYOR SYSTEM [76] Inventor: Otto J. Batik, 1919 S. Harlem Ave., Berwyn, Ill. 60402 [22 Filed: Apr. 27, 1972 211 App]. No.: 243,313

[52] US. Cl. 198/85 [51] 'Int. CL. B65g 37/00 [58] Field of Search 198/ 85 [56] References Cited UNITED STATES PATENTS 1,635,406 7/1927 Greer 198/85 1,811,545 6/1931 Goddard l98/85 X Primary Examiner-Edward A. Sroka AltorneyAlberts, Brezina & Lund Oct. 9, 1973 [5 7] ABSTRACT Product conveyor system wherein a plurality of separate product carriers are provided in the form of generally flat rectangular grates. Each carrier is moved by an upward shuttle from a lowermost station of a first stack and thence through a plurality of intermediate stations to an uppermost station of the first stack, thence by a first transverse shuttle to the uppermost station of a second stack, thence by downward shuttle through a plurality of intermediate stations to a lowermost station of the second stack and thence by a second transverse shuttle back to the lowermost station of the first stack. Loading and unloading conveyors deliver and receive products to and from the lowermost carriers of the first and second stacks. Important features relate to the construction and operation of the shuttles and to the delivery of the product from the loading conveyor and to the unloading conveyor.

23 Claims, 44 Drawing Figures PATENTEDUET e 3,763,991

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mwm own Em PRODUCT convsvon SYSTEM This invention relates to a product conveyor system and more particularly to a compact system in which a large quantity of a product can be positioned in a space of minimum dimensions while the product is continuously delivered at relatively high speed to and from the system. The system is readily and economically constructed while being rugged, durable and highly reliable and is usable in a wide variety of applications.

Many product processing applications require that a product be conveyed to and from a processing or storage region in which it may stay for a substantial length of time. By way of example, in the case of food products requiring baking or freezing, it is necessary that the product be kept in an oven or freezing chamber for a substantial length of time and it is, of course, desirable that a substantial quantity of the product be kept in the chamber in a compact manner while also allowing feeding of the product to and from the chamber at relatively high speeds.

In one type of prior art system, a spiral conveyor has been provided with the product being moved in a spiral path at a linear speed equal to the speed of loading and unloading conveyors. In another type, as exemplified by the Fooks Pat. No. 1,570,235, a conveyor is provided which is moved in a circuitous path. In a further type as exemplified by the Birdseye Pat. No. 2,228,998, a product is carried by rotating annular shelves, one above another, being rotated through one turn by each shelf and dropped to the next lower shelf. In still another type as exemplified by the Patterson Pat. No. 2,679,323, carriers are providing having a plurality of vertically spaced open ended shelves, each carrier being shifted downwardly to sequentially position the shelves therein between loading and unloading conveyors, thence horizontally through a plurality of positions, thence upwardly and thence horizontally through a plurality of positions back to the initial position. As the product is pushed intoeach shelf, the processed product is pushed out of the shelf to the unloading conveyor.

Such systems have a number of disadvantages including complexity and expense of construction, unreliability and the need for unduly large space requirements. They are also quite limited as to the type of product which can be handled in a system designed for one particular product is not suitable for products of substantially different character.

This invention was evolved with the general object of overcoming the disadvantages of prior art systems and of providing a system in which a large amount of a product can be compactly positioned in a space of minimum dimensions while the product is readily delivered to and received from the system at a high speed.

Another object of the invention is to provide a system which is readily and economically constructed while being highly reliable as well as rugged and durable.

A further object of the invention is to provide a systern which is readily adaptable for handling a wide variety of types of products in a wide variety of processing and storage applications.

In accordance with this invention, a system is provided in which a plurality of separate product carriers are arranged in first and second stacks, each stack defining a plurality of vertically aligned product carrier positions including lowermost and uppermost positions and a plurality of intermediate positions. Upward shuttle means are associated with the first stack for simultaneously shifting all carriers thereof upwardly to the next higher position, upper transverse shuttle means are provided for shifting a carrier from the uppermost position of the first stack to the uppermost position of the second stack, downward shuttle means are pro vided for shifting the carriers in the second stack downwardly and lower transverse shuttle means are provided for shifting the carrier from the lowermost position of the second stack to the lowermost position of the first. With this arrangement, each carrier is moved in a circuitous path upwardly through the first stack transversely to the top of the second, downwardly through the second stack and transversely back to the initial position.

In accordance with important features, loading conveyor means deliver a product to a carrier in one position of the first stack while unloading conveyor means receive a product from a carrier in one position of the second stack. Preferably, the loading and unloading positions are in generally horizontal alignment and most preferably, they are the lowermost positions of the first and second stacks. Thus product is stored on all carriers except a carrier or carriers being transferred by the lower transverse shuttle.

According to a specific feature of the invention, each of the carriers defines support means substantially in a horizontal plane for underlying and supporting the product. Preferably, for product in the form of discrete separate items such as packages to be frozen, for example, each carrier is in the form of a gate.

Another important feature relates to the provision of means for effecting operation of the shuttle means periodically and in properly synchronized relation and with the time period between operations of the shuttle means being correlated to the speed of movement of the loading and unloading conveyors.

' In accordance with a further feature, the lower transverse shuttle means includes means for bringing a carrier to a position in which product is received from the loading conveyor at one end of the carrier, the carrier being then moved at the same speed as the loading conveyor to receive the product along the surface thereof.

Additional important features of the invention relate to the construction and operation. of the shuttle means and particularly the upward and downward shuttle means such that a rugged support for the carriers is obtained and such that the carriers are'moved with a high degree of reliability without however requiring a complicated and expensive mechanism.

This invention contemplates other objects, features and advantages which will become more fully apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate a preferred embodiment and in which:

FIG. 1 is a view illustrating diagrammatically and schematically the movements of product and carriers in a system constructed in accordance with the invention;

FIG. 2 is a top plan view of diagrammatic form which serves as a reference for location of various sectional views and which particularly illustrates support and actuating means for vertically reciprocable frames of upward and downward shuttle means;

FIG. 3 is a side elevational view of a diagrammatic form similar to FIG. 2, also particularly illustrating the support of the reciprocable shuttle frames;

FIGS. 4A and 48 together form a cross-sectional view, taken substantially along line IV-IV of FIG. 2;

FIGS. 5A and 58 together form a sectional view taken substantially along line VV of FIG. 3;

FIGS. 6A and 68 together form a sectional view taken substantially along line VI-VI of FIG. 3;

FIG. 7 is a sectional view taken substantially along line VII-VII of FIG. 2 and illustrating portions of an upward shuttle mechanism;

FIG. 8 is a sectional view taken substantially along line VIII-VIII of FIG. 2 and forming a side elevational view of the structure shown in FIG. 7;

FIG. 9 is a sectional view taken substantially along line lX--IX of FIG. 7 and illustrating the operation of a pilot finger of a lifting finger assembly;

FIG. 10 is a sectional view taken substantially along line XX of FIG. 7 and illustrating the operation of a pilot finger of a station finger assembly;

FIG. 11 is a sectional view taken substantially along line XIXI of FIG. 2 and illustrating portions of a downward shuttle mechanism;

FIG. 12 is a sectional view taken substantially along line XII-XII and forming a side elevational view of the structure shown in FIG. 11;

FIG. 13 is a sectional view taken substantially along line XIII-XIII of FIG. 11 and illustrating the operation of a pilot finger of a lowering finger assembly;

FIG. 14 is a sectional view taken substantially along line XIV-XIV of FIG. 11 and illustrating the operation of a pilot finger of a station finger assembly;

FIG. 15 is an elevational view of a portion of a lifting frame, illustrating the support of lifting fingers thereon;

FIG. 16 is a side elevational view of the structure shown in FIG. 15;

FIG. 17 is a sectional view taken substantially along line XVII-XVII of FIG. 15;

FIG. 18 is an elevational view showing the support of station fingers on the frame of the apparatus;

FIG. 19 is a side elevational view of the structure shown in FIG. 18;

FIG. 20 is a sectional view taken substantially along line XX-XX of FIG. 18;

FIG. 21 is a detail view, on an enlarged scale, illustrating the form and support of a cam which functions to operate pilot fingers of a lifting finger assembly; 7

FIG. 22 is a top plan view of the structure shown in FIG. 21;

FIG. 23 is a detail view, on an enlarged scale, illustrating in elevation the form and support of a cam used for operation of a pilot finger of a station finger assemy;

FIG. 24 is a top plan view of the structure shown in FIG. 23;

FIG. 25 is a detail view, on an enlarged scale, showing the form and support of a cam which operates a pilot finger for servicing fingers of the downward shuttle mechanism;

FIG. 26 is a top plan view of the structure as shown in FIG. 25;

FIG. 27 is a detail view, on an enlarged scale, showing the form and support of a cam which operates a pilot finger for station fingers of the downward shuttle mechanism;

FIG. 28 is a top plan view of the structure shown in FIG. 27;

FIG. 29 is a top plan view of one of the carriers in the system; I

FIG. 30 is a side elevational view of the carrier as shown in FIG. 29;

FIG. 31 is a detail view, on an enlarged scale, showing in plan the support of a finger on a chain in a transverse shuttle mechanism;

FIG. 32 is a side elevational view of the structure shown in FIG. 31;

FIG. 33 is a detail view, on an enlarged scale, showing in plan a one-way gate device of a carrier support track permitting upward movement of the carrier therebeyond while preventing downward movement;

FIG. 34 is a side elevational view of the structure shown in FIG. 33;

FIG. 35 is a sectional view taken substantially along line XXXV-XXXV of FIG. 34;

FIG. 36 is a view illustrating diagrammatically the drive of shuttle chains in the system;

FIG. 37 is another diagrammatic view illustrating the unloading conveyor and empty great return shuttle chain, taken substantially along line XXXVII-XXX- VII of FIG. 36;

FIG. 38 is another diagrammatic view illustrating the drive of loading and auxiliary shuttle chains from a loading conveyor, taken substantially along line XXXVIll-XXXVIII of FIG. 36;

FIG. 39 is a plan view illustrating the drive of upper cross-over shuttle chains, taken substantially along line XXXIX-XXXIX of FIG. 36;

FIG. 40 is a diagrammatic sectional view taken substantially along line XXXX-XXXX of FIG. 38; and

FIG. 41 is a schematic diagram showing the energization of a solenoid valve for operation of an air cylinder of the system.

Referring to FIG. 1, reference numeral 10 generally designates a conveyor system constructed in accordance with the principles of the invention. The system 10 comprises a plurality of product carriers, 17 carriers 11-27 being provided in the illustrated system. It will be understood that a lesser or greater number of carriers may be provided, according to requirements.

Each of the carriers 11-27 may be in the form of a grate structure as hereinafter described, in connection with FIGS. 29 and 30, and each defines support means in a horizontal plane for underlying and supporting a product. First and second stack means, as also described hereinafter are provided, each arranged for supporting a plurality of the carriers and each defining a plurality of vertically aligned product carrier positions or stations. As shown in FIG. 1, the carrier 11 is moving into a lowermost position or station of the first stack means, the carriers 12-17 are in intermediate stations of the first stack means, the carrier 18 is moving transversely from the uppermost station of the first stack to the uppermost station of the second stack means, the carriers 19-25 are in intermediate positions of the second stack means, the carrier 26 is moving transversely out of the lowermost station of the second stack means andthe carrier 27 is in a station awaiting movement into the lowermost station of the first stack means.

The carrier 11, as shown in FIG. 1, is being moved to the left, receiving product from the left end of a loading conveyor 29, the carrier 11 being preferably moved at a speed approximately equal to the speed of movement of the product by the loading conveyor 29. The product, as illustrated, may be in the form of separate discrete items 30 such as, for example, packages of food to be frozen, but it will be understood that the invention is not limited to any particular form of product and, on the contrary, an important feature of the system is that it can readily handle various types of product without any modifications in construction.

While the carrier 11 is being moved to the left, the carrier 26 is moving to the right, the product items 30 supported thereon being engaged by a stationary backup bar 31 to be dropped from the left-hand end of the carrier 26 on to an unloading conveyor 32, which moves the product to the left, preferably at approximately the same speed as the movement of the product on the loading conveyor 29.

When the carrier 11 is moved to a position such that it fully occupies the lowermost station of the first stack and is fully loaded with product, the carrier 18 will fully occupy the uppermost station of the second stack and the carrier 26 will have been moved fullyout of the lowermost station of the second stack. At this point, a shuttle cycle is initiated in which each of the carriers 11-17 in the first stack is moved to a next higher station and each of the carriers 18-25 in the second stack is moved to a next lower station. At the same time, the carrier'27 is moved upwardly to a position in which the left-hand portion thereof is immediately under the lefthand end of the loading conveyor 29. This cycle of operation is completed within a relatively short interval of time and thereafter, the carrier 27 is moved to the left to receive product from the loading .conveyor. At the same time, the carrier 17 is moved from the uppermost station of the first stack toward the uppermost station of the second stack and the carrier 25, now positioned in the lowermost station of the second stack, is moved to the right, product thereon being pushed therefrom onto the unloading conveyor 32 through the operation of the stationary back-up bar 31. Aseach carrier becomes fully loaded in the lowermost station of the first stack, the shuttle cycle is again repeated. Thus, each carrier is progressively moved upwardly through the first stack as indicated by arrow 33, thence transversely from the uppermost station of the first stack to the up permost station of the second, as indicated by arrow 34, thence downwardly to the lowermost station of the second stack, as indicated by arrow 35, thence transversely as indicated by'arrow 36, thence upwardly as indicated by arrow 37 and finally transversely back to the initial position. It is noted that all of the carriers with the exception of the carrier in the position of carrier 27 are active, being eitherfully loaded, being in the process of being loaded or being in the process of being unloaded FIGS. 2 and. 3 diagrammatically illustrated fixed frame structure of the system and also vertically reciprocable frame structures of the upward and downward shuttles. A fixed frame structure, generally designated by reference numeral 34, includes a pair of spaced upright channels 35 and 36 at the left, another pair of spaced upright channels 37 and 38 at an intermediate position and a third pair of spaced upright channels 39 and 40 at the right. A pair of horizontal members 41 and 42 extend from the upper ends of the channels 35 and 36 to the upper edges of the channels 37 and 38 and another pair of horizontal members 43 and 44 extend from the upper ends of the channels 37 and 38 to the upper ends of channels 39 and 40 and therebeyond to terminal ends connected by a cross member 45. Another cross member 46 connects the upper ends of channels 35 and 36. Other cross members, not shown, are placed at lower levels to contri-bute to the rigidity of the fixed frame assembly.

An upward shuttle is provided which includes a vertically reciprocable frame structure 50 including lower and upper horizontal members 51 and 52 and upright end members 53 and 54, a set of members similar to the members 51-54 being provided on the rearward por tion of the frame structure and being connected to members 51-54 through suitable cross members to form a generally rectangular frame. The lower frame member 51 is extended to the right and is connected to member 54 through an angle brace 55. Four front guides 50A and a similar set of four rear guides are mounted on the fixed frame structure to guide the frame structure 50 in its up and down movement.

A downward shuttle frame 56 is provided including lower and upper horizontal members 57 and 58 and upright end members 59 and 60, a set of members similar to the members 57-60 being provided on the rearward portion of the frame structure and being connected to members 57-60 through suitable cross members to form another generally rectangular frame structure. Four front guides 56A and a similar set of four rear guides are mounted on the fixed frame structure to guide the shuttle frame structure 56 in its up and down movement.

The upward shuttle frame 50 normally rests on two horizontal angles 61 and 62 respectively secured between the upright channels 37 and 38 and the upright channels 39 and 40. During the shuttle cycle, the frame 50 is moved upwardly to a position at which the member 52 is positioned as indicated in dotted lines in FIG. 3 and thence back to the position as'illustrated in full lines. This movement is effected by means of four cables 63-66, cables 63 and 64 being connected to the left end of the frame 50 through suitable turnbuckles 67 and cables 65 and 66 being connected to the right end of the frame through turnbuckles 68, the turnbuckles 67 and 68 being adjustable for leveling purposes. Cables 63 and 64 make a 90 turn on a pair of sheaves 69 and 70 on a horizontal shaft 71, are guided over parts of a pair of double sheaves 73 and 74 on a horizontal shaft 75 and are connected'to parts of another pair of double sheaves 77 and 78 on a horizontal shaft 80. Cables 65 and 66 make'a 90 turn on the other parts of the double sheaves 73 and 74 and are connected to the other parts of the double sheaves 77 and 78. When shaft 80 is rotated through a predetermined angular distance, which may be on the order of 90, the upward shuttle frame 50 is moved from the position illustrated in full lines to the position in which the frame member occupies the position indicated in dotted lines in FIG. 3.

The downward shuttle frame 5 6 normally occupies the position indicated in full lines in FIG. 3, but during the shuttle cycle is moved downwardly to a position in which the frame member 50 thereof occupies the position indicated in dotted lines in FIG. 3 and in which the frame 56 rests on two horizontal angles 81 and 82 respectively secured between upright channels 35 and 36 and upright channels 37 and 381. Such movement is controlled through four support cables 83-86, cables 83 and 84 being connected to the left side of the frame through turnbuckles 87 and cables 85 and 86 being connected to right portions of the frame 56 through turnbuckles 88. Cables 83 and 84 make a 90 turn on a pair of sheaves 89 and 90 on horizontal shafts 91 an 92, pass over parts of a pair of double sheaves 93 and 94 on a horizontal shaft 96 and are fixedly connected to parts of another pair of double sheaves 97 and 98 which are secured to the shaft 80. Cables 85 and 86 make a 90 turn on the other parts of the double sheaves 93 and 94 and are fixedly connected to the other parts of the double sheaves 97 and 98.

It is noted that the connections of the cables 63-66 for the upward shuttle frame 50 are to the upper sides of the sheaves 77 and 78 whereas the connections of the cables 83-86 are to the lower sides of the sheaves 97 and 98. Thus with clockwise rotation of the shaft 80, as viewed in FIG. 3, the upward shuttle frame 50 is moved upwardly while the downward shuttle frame 66 is moved downwardly. It is also noted that the sheaves 97 and 98 have a diameter substantially greater than that of the sheaves 77 and 78 so that the vertical movement of the downward shuttle 56 is substantially greater than that of the upward shuttle 50. This feature is important in securing proper operation of the shuttles as will be clarified hereinafter.

To actuate the shaft 80, an arm 100, rigidly secured thereto, is povitally connected to the end of a piston rod 101 of an air cylinder unit 102 which is pivotally carried between supports 103 and 104 carried from the fixed frame structure. When air is supplied to the cylinder 102 to actuate the rod 101 as hereinafter described, the rod 101 actuates the arm 100 through a predetermined angle, which may be on the order of 90 to actuate the frames 50 and 56 as above described. During this movement, the cylinder 102 may pivot slightly in a counterclockwise direction. Movement of the cylinder 102 in a clockwise direction is limited by a member 103, as diagrammatically illustrated in FIG. 3. It is noted that the weights of the shuttle frames 50 and 56 and the arrangement of the supports may preferably be such that the shuttle frames are urged to the positions as illustrated.

With regard to the upward shuttle operation, in general, each carrier is normally supported at four corner portions thereof by four station fingers supported from the stationary frame structures. When the upward shuttle frame 50 is moved upwardly, each carrier is lifted by four lifting fingers, carried by the frame 50, to a position above the station fingers for the next higher station, which are pivoted, about a vertical axis, out of the way. The station fingers are then pivoted back to the support position and the frame 50 is lowered, the lifting fingers being pivoted, about a vertical axis, to a position such as to clear the next lower carrier, the lifting fingers then being pivoted back to the initial position, to be.

ready to perform another lifting operation.

With regard to the downward shuttle operation, each carrier is normally supported at four comer portions by four lowering fingers carried by the downward shuttle frame 56. In the normal position, each carrier is positioned a short distance above four station fingers supported from the stationary frame structure. When the downward shuttle frame 56 is lowered, such station fingers are pivoted out of the way but as the carrier approaches the next lower position, the station fingers of the next lower station are pivoted into a supporting position to receive the carrier. The fingers supported by the frame 56 then move further downward, pivot, come up past and clear the carrier and then pivot back and lift the next higher carrier from the station fingers, completing the cycle.

These operations will be clarified hereinafter, but it is here noted that the fingers carried by the downward shuttle frame 56, although serving the primary function of lowering the carriers, also serve lifting functions during the shuttle cycle as well as support functions in the time intervals between shuttle cycles. For these reasons, such fingers carried by the vertically reciprocable frame 56 are referred to as servicing" fingers. Similarly, the fingers carried by the upward shuttle frame 50, although primarily serving the function oflifting the carriers, also perform a lowering operation during part of the cycle and such fingers are also referred to as servicing fingers. Thus, servicing fingers are those carried from one or the other of the vertically reciprocable frames 50, 56 while station" fingers are those supported from the stationary frame structure 34.

Before going into'the details of the shuttle mechanisms it is believed that it will be helpful to understand the construction of the carriers in the illustrated system, the construction of the carrier 11 being shown in FIGS. 29, and 30, the other carriers 12-27 all having the same construction. Referring to FIGS. 29 and 30, the carrier 11 comprises four spaced parallel downwardly open channel members, including two end members 107 and 108 and two intermediate members 109 and 1 10, members 107-1 10 being welded or otherwise rigidly secured to and connected by two sets of angle members 111 and 112 spaced inwardly from the ends of the members 107-110, each set having one part extending between members 107 and 109, a second part extending between members 109 and 110 and a third part extending between members 108 and 110. Disposed between the angle members 111 and 112 are a plurality of spaced parallel bars 1 14 which are welded or otherwise secured to the members 107-110. The carrier 1 1 is thus in the form of an open grate structure, desirable for many types of product. It will be understood, however, that the carrier may provide an imperforate supporting surface, if required for a particular application. 7

As illustrated, the spacing between the end channel member 107 and the intermediate channel member 109 is greater than that between the opposite end channel member 108 and the adjacent intermediate channel member 110. This has a definite purpose which will be clarified hereinafter in connection with the transverse shuttle operations.

The sectional view of FIGS. 4A and 4B shows rearward members of the upward shuttle frame, including members 51A, 52A, 53A and 54A, respectively positioned behind the members 51, 52, 53 and 54 shown in the front view of FIG. 3. Similarly, FIG. 4A shows members 57A, 58A, 59A and 60A of the downward shuttle frame 56, respectively positioned behind the members 57, 58, 59 and 60 shown in the front view of FIG. 3.

The upward shuttle mechanism comprises four servicing finger assemblies, a left-hand rearward assembly being shown in FIG. 4. This assembly includes servicing fingers 115-121 projecting transversely from a vertical rod 122 which is supported from the left-hand rearward vertical frame member 53A for pivotal movement about a vertical axis, the support of the rod 122 being illustrated in FIGS. 15-17, described hereinafter.

The upward shuttle mechanism further includes four station finger assemblies. The left-hand rearward station finger assembly, shown in FIG. 4A, comprises station fingers 123-128 projecting transversely from a vertical rod 130 which is supported from the channel member 38 of the stationary frame for pivotal movement about a vertical axis, in a manner as shown in FIGS. 18-20, described hereinafter.

The upward shuttle mechanism further includes left- .hand front servicing and station finger assemblies,

right-hand front servicing and station finger assemblies and right-hand rear servicing and station finger assemblies, the latter being shown in FIG. 4B and including servicing fingers 131-137 on a rod 138 and station fingers 139-144 on a rod 146.

In the operation of the upward shuttle mechanism as thus far described, the carriers 12-17 are normally supported on the station fingers 123-128 of the left-hand rear assembly, the station fingers 139-144 of the righthand rear assembly and similar station fingers of the left and right hand front station finger assemblies. The carrier 11 is supported for horizontal slidable movement by a rearward stationary angle member 148 and a similar front stationary angle member and ismoved to the left by a chain assembly as hereinafter described. When the carrier 11 is moved to the left to fully occupy the lowermost station of the first or right-hand stack, the channel member 107 thereof overlies the servicing finger 115 while the channel member 108 thereof overlies the servicing finger 131 and as shown in FIGS. 4A and 48, similar channel members of the carriers 12-17 overlie the servicing fingers 116-121, the servicing fingers 132-137 and similar servicing fingers of the left and right-hand front servicing finger assemblies. When the upward shuttle frame 50 is then moved upwardly, the servicing fingers engage and lift the carriers 11-17. During the initial portion of such lifting movement, the vertical rods 130 and 148 are pivoted about their verti- -cal axes to move the station fingers 123-128 and 139-144 out of the way to allow each carrierto be lifted to a position above the station finger for the next higher station. The station fingers are then pivoted back to the initial position whereupon the upward shuttle frame 50 is moved back downwardly to the initial position to allow the carriers to rest upon the station fingers.

During the upward shuttle operation, the uppermost carrier 17 is lifted to a position in which it can be moved to the left to the uppermost position of the other stack. During such movement, the rearward ends of the intermediate channels of the carrier 17, corresponding the intermediate channels 109 and 1 of the carrier 1 1 as shown in FIGS. 29 and 30, engage a pair of short angle members 149 and 150 which, as hereinafter described, are pivotal about horizontal axes and are spring urged to the illustrated positions. When the carrier 17 is moved to a position substantially above the members 149 and 150, they snap back to the illustrated position so that when the carrier 17 is lowered, the rearward ends of the intermediate channels thereof rest on the members 149 and 150. A similar pair of members are provided for supporting the front ends of the intermediate channels. Additional stationary rearward angle members 151, 152 and 153 and similar from angle members are provided for supporting the carrier for horizontal slidable movement to the uppermost position of the other stack.

The carrier 18 is shown in a position in which it is moving to the left toward a position fully occupying the uppermost station of the second stack. In this position, the rearward ends of the channels of the carrier 18 rest upon horizontal leg portions of a stationary angle member 155, which has openings 156 and 157 in the horizontal leg thereof through which the rear ends of the intermediate channels of the carrier can move downwardly when the carrier reaches a position fully to the left. The spacing of opening 156 from the left end of member 155 is greater than the spacing of opening 157 from the right end, corresponding to the location of the intermediate channel members of the carriers in nonsymmetrical relation. A similarangle member with similar openings is provided at the front.

To move the carrier 18 to the left, a finger 150 is carried by a chain 160, entrained on suitable sprockets 161 and 162, the finger 150 being engaged with the left-hand end channel of the carrier 18. Finger 1'59 moves the carrier 18 to the left until the left end of the carrier engages a fixed stop 163 which is spacedfrom the left end of angle member by a distance greater than the width of the'left end channel member of the carrier. At this point the intermediate channel members are aligned with the openings 156 and 157 and the right end channel member is aligned with a space between the right end of angle member 155 and the left end of member 155, allowing the carrier to droponto the downward shuttle. The support and operation of the finger 159 is illustrated and described in detail in connection with FIGS. 31 and 32.

The downward shuttle mechanism is similar to the upward shuttle mechanism in that itcomprises four servicing finger assemblies and four station finger assemblies, the left and right-hand assemblies being shown in FIG. 4A. The left-hand rear servicing finger assembly comprises fingers -170 projecting transversely from a vertical rod 172 while the left-hand rear station finger assembly comprises fingers 173-177 projecting transversely from a vertical support rod 178. The servicing finger rod 172 is supported from the downward shuttle frame 56 while the station finger support rod 178 is supported from the stationary frame of the system. Similarly, a right-hand rear servicing finger assembly is provided comprising fingers 181-186 projecting transversely from a vertical rod 188 and a station finger assembly is provided comprising fingers 189-193 projecting transversely from a verticall rod 194. Similar left and right-hand front servicing and station finger assemblies are provided.

It is here noted that the rods 172, 178, 188 and 194,

as well as other vertically extending members in the system are shown with intermediate portions broken away to facilitate illustration and also to indicate that as many stations may be provided in each stack as may be desirable in a particular application of the system. Thus, in FIG. 4A, carriers 22 and 23 referred to in connection with the illustration of FIG. 1, are not shown and the corresponding servicing and station fingers are also not shown.

As shown in FIG. 4A, the rear ends of the opposite end channel members of the carriers 19, 20, 21, 24 and 25 rest on the servicing fingers 166-170 and 182-186 and when the carrier 18 is moved fully to the left, to a.

position such that the rear ends of the intermediate channels thereof are aligned with the openings 156 and 157, the rear ends of the end channels thereof will rest on the servicing fingers 165 and 181. When the downtion fingers 173-177 and 189-193, as well as similar station fingers of the front assemblies are pivoted out of the way to permit the respective carriers to pass to a lower position after which the station fingers are returned to the initial position. Thus, station finger 173, for example, is pivoted out of the way, to permit the carrier 19 to move downwardly therebelow whereupon the station fingers are pivoted back so that the carrier 18 will rest temporarily on the station finger 173, carrier 19 will rest temporarily on the station finger 174, etc. In this connection, the downward shuttle frame 56 is moved downwardly through a vertical distance substantially greater than twice the nominal vertical distance between stations. By way of example, and not by way of limitation, the vertical distance between stations may be 4 inches while the distance of movement of the downward shuttle frame may be 9 inches.

After depositing the carriers on the station fingers temporarily, the servicing fingers continue their downward movement without pivoting, until the limit of downward travel is reached. Then, in upward travel, the servicing fingers are pivoted to clear the carrier and are then pivoted back to pick up the next higher carrier and lift it from the station fingers. For example, the finger 165 will lower the carrier 18 until it rests temporarily on the station finger 173, then moves further downwardly, then moves upwardly while pivoting to clear the carrier 18 and move back upwardly to the illustrated position in readiness to receive the next carrier 17. The servicing finger 166 moves downwardly to move the carrier 19 downwardly past the station finger 173, then deposits the carrier 19 on the station finger 174, then moves further downwardly and then upwardly while pivoting to clear the carrier 19 and then back to pick up the carrier 18, then deposited temporarily on the station finger 173 and finally to the position as illustrated, in which it will then support the carrier 18, rather than the carrier 19. The lowermost servicing finger 170 will move the carrier 25 downwardly past the station finger 177, then pivoted out of the way, and further downwardly until the carrier rests on a rearward stationary angle member 196 and a similar front angle member. The servicing finger 170 moves further downwardly, then upwardly while pivoting to clear the carrier 25 and then back to pick up the carrier 24, then deposited on the station finger 177 and to then move the carrier 24 to the position in which carrier 25 is illustrated.

In the illustrated system, the vertical support rods for the servicing and station fingers both the upward and downward shuttles are actuated from movement of the shuttle frames through pilot finger and cam assemblies illustrated in FIGs. 7-14 and 21-28, described in detail hereinafter.

The carrier 26 is shown in the process of being moved to the right in FIGS. 4A and 4B. This movement is effected by a transverse shuttlemechanism which includes a finger 197 carried by one link of a chain 198 entrained about a pair of sprockets 199 and 200. During such movement of the carrier 26, product is removed therefrom by operation of the back-up bar 31 to be deposited on the unloading conveyor which includes a belt 202 entrained rollers including a roller 203, the upper portion of the belt 202 being slightly below the support rail or angle 196 and the corresponding rail or angle at the front. When. the carrier 26 reaches a position such as to be completely out of the lowermost station of the downward shuttle stack and such thatthe right end thereof is adjacent the left end of the carrier 26, the carrier 27 is lifted from a stationary support rail or angle 205 at the rear of the system, aligned with the angle 196, and a correspondingly rail or angle at the front. Lifting of the carrier 27 is effected by means of a pair of fingers 207 and 208 which are supported through upright supports 209 and 210 from the extension of the lower rear horizontal frame member 51a of the upright shuttle, a similar pair of fingers being supported from the extended portion of the front frame member 51. After the shuttle cycle is completed, and after the fingers 208 and 207 and corresponding front fingers are lowered, the carrier 26 is moved to the right to the position in which carrier 27 is shown in FIG. 4B.

When the carrier 27 is lifted, the rearward ends of the intermediate channels thereof engage a pair of short angle sections 211 and 212, which are pivoted about horizontal axes and which are spring urged to the illustrated position. After the carrier 27 is lifted to a predetermined extent, the sections 211 and 212 snap back to the illustrated position to receive the rear ends of the intermediate channels of the carrier 27 when the upright shuttle frame 50 is lowered. Angle sections similar to the sections 211 and 212 are provided for operative association with the front ends of the intermediate carrier channels.

After the carrier 27 is lifted to rest on the sections 211 and 212, the left-hand one of the intermediate channels thereof is engaged by a finger 213 of an auxiliary shuttle, finger 213 being supported on a link of a chain 214 entrained on a pair of sprockets 215 and 216. The carrier is moved a short distance to the left by the finger 214, being supported by rearward angle sections 217, 218, 219 and 220 aligned with the angle sections 211 and 212, similar front angle sections being also provided. After being moved a short distance to the left by the finger 213 of the auxiliary shuttle, the

left-end channel of the carrier is engaged by a finger 222 carried by a link of a chain 223 which is entrained on sprockets 224 and 225. As shown in FIG. 4A, the finger 222 is engaged with the channel 107 of the carrier 11, in the process of moving the carrier 11 to the left.

It is noted that when the carrier 27 is being moved upwardly, the left-hand end portion thereof is to the left of the end of the loading conveyor 29 which comprises a suitable belt 227 entrained on guide rollers including the roller 228. An angle plate 229 may be provided to direct the product angularly downwardly on to the receiving carrier.

The sectional view of FIGS. 4A and 4B show only the components and the rearward portion of the apparatus and some of the corresponding frontward components are shown in the sectional views of FIGS. 5A and 5B and FIGS. 6A and 68. With reference thereto, the lefthand front upward shuttle assembly includes vertical support rods 233 and 234, respectively corrresponding to vertical support rods 122 and and having servicing and station fingers projecting therefrom. The righthand front upward shuttle assembly includes vertical support rods 235 and 236 for servicing and station fingers. 

1. In a product conveying system, first and second stack means in adjacent relation each arranged for supporting a plurality of separate product carriers, each of said stack means defining a plurality of vertically aligned product carrier stations including lowermost and upper-most stations and a plurality of intermediate stations, upward shuttle means associated with said first stack means for simultaneously shifting each carrier therein upwardly to the next higher station, upper transverse shuttle means for shifting a carrier from the uppermost station of said first stack means to the uppermost station of said second stack means, downward shuttle means associated with said second stack means for simultaneously shifting each carrier thereof downwardly to the next lower station, lower transverse shuttle means for shifting a carrier from the lowermost station of said second stack means to the lowermost station of said first stack means, loading conveyor means for supplying a product to a carrier in one station of said first stack means at a certain linear speed, and receiving means for effecting receiving movement of the product onto the surface of a carrier in said one station at said certain linear speed, said receiving means being effective to move a carrier from a position under said loading conveyor means and into said one station at said certain linear speed.
 2. In a system as defined in claim 1, loading conveyor means for supplying a product to a carrier in one station of said first stack means, and unloading conveyor means for receiving a product from a carrier in one station of said second stack means.
 3. In a system as defined in claiM 2, said one station of said first stack means, said one station of said first stack means and said one station of said second stack means being in generally horizontal alignment.
 4. In a system as defined in claim 2, said one station of said first stack means being the lowermost station thereof, and said one station of said second stack means being the lowermost station thereof.
 5. In a system as defined in claim 2, said input and output conveyors being operable to move the product horizontally at approximately the same speed.
 6. In a system as defined in claim 5, said upward, downward and first and second transverse shuttle means being operable periodically with the time period between operations being approximately equal to the dimensions of each carrier in a direction parallel to the direction of movement of said conveyor means divided by the speed of movement of said conveyor means.
 7. In a system as defined in claim 1, wherein said one station of said first stack means is the lowermost station thereof, said second transverse shuttle means including means for moving a carrier from the lowermost station of said second stack means to said position under said loading conveyor, said receiving means being thereafter effective to move said carrier into said lowermost station of said first stack means.
 8. In a system as defined in claim 1, each of said carriers defining support means in a horizontal plane for underlying and supporting the product.
 9. In a system as defined in claim 8, each of said carriers being in the form of an open grate structure.
 10. In a product conveying system, first and second stack means in adjacent relation each arranged for supporting a plurality of separate product carriers, each of said stack means defining a plurality of vertically aligned product carrier stations including lowermost and uppermost stations an a plurality of intermediate stations, upward shuttle means associated with said first stack means for simultaneously shifting each carrier therein upwardly to the next higher station, upper transverse shuttle means for shifting a carrier from the uppermost station of said first stack means to the uppermost station of said second stack means, downward shuttle means associated with said second stack means for simultaneously shifting each carrier thereof downwardly to the next lower station, and lower transverse shuttle means for shifting a carrier from the lowermost station of said second stack means to the lowermost station of said first stack means, said upward shuttle means comprising vertically reciprocable frame means, servicing fingers carried by said frame means for operating during upward movement of said frame means to lift each carrier from one station to a next higher station.
 11. In a system as defined in claim 10, means for effecting movement of said servicing fingers during downward movement of said frame means to clear the respective carriers during said downward movement.
 12. In a system as defined in claim 11, said movement-effecting means comprising cam and cam follower means.
 13. In a system as defined in claim 10, a plurality of vertical rod means each arranged to support a plurality of said servicing fingers in vertically spaced relation thereon, each of said vertical rod means being pivotal about a vertical axis during downward movement of said frame means to cause said fingers thereon to clear the respective carriers.
 14. In a system as defined in claim 13, pilot finger means carried by said vertical rod means, and cam means engagable by said pilot finger means to effect pivotal movement of said vertical rod means.
 15. In a system as defined in claim 14, said cam means being pivotally supported and being urged to predetermined positions, said cam means being pivotal by said pilot finger means out of said positions during upward movement of said frame means and being then ineffective to move said pilot finger means, and said cam means being held in said preDetermined positions during downward movement of said frame means to camminingly effect movement of said pilot finger means.
 16. In a product conveying system, first and second stack means in adjacent relation each arranged for supporting a plurality of separate product carriers, each of said stack means defining a plurality of vertically aligned product carrier stations including lowermost and uppermost staions and a plurality of intermediate stations, upward shuttle means associated with said first stack means for simultaneously shifting each carrier therein upwardly to the next higher station, upper transverse shuttle means for shifting a carrier from the uppermost station of said first stack means to the uppermost station of said second stack means, downward shuttle means associated with said second stack means for simultaneously shifting each carrier thereof downwardly to the next lower station, and lower transverse shuttle means for shifting a carrier from the lowermost station of said second stack means to the lowermost station of said first stack means, said upward shuttle means comprising station fingers for supporting a carrier in each of said stations of said first stack means, and means for effecting outward movement of said station fingers to allow movement of each carrier to a next higher position.
 17. In a system as defined in claim 16, a plurality of vertical rod means, each arranged to support a plurality of said station fingers in vertically spaced relation thereon.
 18. In a system as defined in claim 17, pilot finger means carried by said vertical rod means, vertically reciprocable frame means, and cam means carried by said frame means for actuating said pilot finger means.
 19. In a system as defined in claim 18, servicing finger means carried by said frame means for lifting each carrier of said first stack means from one station to a next higher station.
 20. In a product conveying system, first and second stack means in adjacent relation each arranged for supporting a plurality of separate product carriers, each of said stack means defining a plurality of vertically aligned product carrier stations including lowermost and uppermost stations and a plurality of intermediate stations, upward shuttle means associated with said first stack means for simultaneously shifting each carrier therein upwardly to the next higher station, upper transverse shuttle means for shifting a carrier from the uppermost station of said first stack means to the uppermost station of the second stack means, downward shuttle means associated with said second stack means for simultaneously shifting each carrier thereof downwardly to the next lower station, and lower transverse shuttle means for shifting a carrier from the lowermost station of said first stack means, said downward shuttle means comprising a vertically reciprocable frame, and servicing finger means on said frame for lowering each carrier in said second stack means from one station to a next lower station.
 21. In a system as defined in claim 20, means operative to effect movement of said servicing fingers to allow clearing of the carriers during an initial portion of upward movement of said vertically reciprocable frame.
 22. In a system as defined in claim 21, station finger means for temporarily supporting said carriers during clearing of said carriers by said servicing finger means.
 23. In a product conveying system, first and second stack means in adjacent relation each arranged for supporting a plurality of separate product carriers, each of said stack means defining a plurality of vertically aligned product carrier stations including lowermost and uppermost stations and a plurality of intermediate stations, upward shuttle means associated with said first stack means for simultaneously shifting each carrier therein upwardly to the next higher station, upper transverse shuttle means for shifting a carrier from the uppermost station of said first stack means to the uPpermost station of said second stack means, downward shuttle means associated with said second stack means for simultaneously shifting each carrier thereof downwardly to the next lower station, lower transverse shuttle means for shifting a carrier from the lowermost station of said second stack means to the lowermost station of said first stack means, back-up bar means associated with one of said transverse shuttle means for removing product from a carrier shifted by said one of said transverse shuttle means, and unloading conveyor means for receiving the product so removed, said unloading conveyor means having a generally horizontal product receiving surface underlying the carrier shifted by said one of said transverse shuttle means and operative to move said product receiving surface in a direction opposite the direction of shifting movement of said carrier. 